Propylene ethylene polymers and production process

ABSTRACT

Ethylene propylene copolymers, substantially free of diene, are described. The copolymers will have a uniform distribution of both tacticity and comonomer between copolymer chains. Further, the copolymers will exhibit a statistically insignificant intramolecular difference of tacticity. The copolymers are made in the presence of a metallocene catalyst.

This application is the National Stage of International Application No.PCT/US02/10515, filed Apr. 02, 2002, which claims the benefit of U.S.Provisional Application No. 60/342,186, filed Dec. 19, 2001 and U.S.Provisional Application No. 60/336,655, filed Dec. 5, 2001.Additionally, this application is a continuation-in-part of U.S.application Ser. No. 09/834,256, filed Apr. 12, 2001, now U.S. Pat. No.6,525,157, which is a continuation-in-part of application Ser. No.09/346,460, filed Jul. 1, 1999, now abandoned, which is acontinuation-in-part of application Ser. No. 09/342,854, filed Jun. 29,1999, now U.S. Pat. No. 6,642,316, which is a continuation-in-part ofapplication Ser. No. 09/108,772, filed Jul. 2, 1998, now abandoned,which is a continuation-in-part of application Ser. No. 09/108,467,filed Jul. 1, 1998, now abandoned, which is a continuation-in-part ofapplication Ser. No. 08/910,001, filed Aug. 12, 1997, now U.S. Pat. No.6,635,715.

FIELD

Embodiments of the present invention include copolymers of ethylene andpropylene, in the substantial absence of dienes. More specifically, thecopolymers are made in a process that employs a single reactor, insteady state.

BACKGROUND

Ethylene propylene copolymers made with metallocene catalysts are known.Many such copolymers are intermolecularly heterogeneous in terms oftacticity, composition (weight percent comonomers) or both. Further,such polymers may also, or in the alternative, be compositionallyheterogeneous within a polymer chain. Such characteristics may be, butare not always, the result of multiple reactor schemes or sequentialaddition of polymer.

The elasticity, flexural modulus and tensile strength of suchcopolymers, when considered in the aggregate, may not reach asatisfactory level for use in commercial elastomeric operation.

U.S. Pat. No. 5,747,621 suggests fractionable reactor blendpolypropylenes, directly obtainable from the polymerization reaction ofpropylene having 30 to 90% by weight of a boiling n-heptane fraction,soluble in xylene at 135° C. In Table 2 of this document, the onlyfractionation disclosed, each of the solvents appears to be at itsboiling point. Further, reference to this table shows that thediethyl-ether fraction has no melting point (amorphous).

In the journal articles Science, Vol. 267, pp 217–219 (1995);Macromolecules, Vol. 31, pp 6908–6916 (1998); and Macromolecules, Vol.32, pp 8283–8290, pp 3334–3340 and pp 8100–8106, propylene polymers withsimilar characteristics as those disclosed in the above discussed U.S.Pat. No. 5,747,621 are made and fractionated. The polymers are made withbis(aryl indenyl) or bisindenyl metallocene catalysts. In these journalarticles, these polymers are fractionated in boiling ether and heptane,leaving a portion of the polymer insoluble in either. The polypropylenesare stated to be compositionally heterogeneous in terms of tacticity andmolecular weight.

U.S. Pat. No. 5,504,172 suggests a propylene elastomer that hasproperties such that:

-   -   (a) the elastomer contains propylene units in an amount of 50 to        95% by mol and ethylene units in an amount of 5 to 50 % by mol;    -   (b) a triad tacticity of three propylene units-chains consisting        of head-to-tail bonds, as measured by ¹³C NMR, is not less than        90.0%; and    -   (c) a proportion of inversely inserted propylene units based on        the 2,1-insertion of a propylene monomer in all propylene        insertions, as measured by ¹³C NMR, is not less than 0.5%, and a        proportion of inversely inserted propylene units based on the        1,3-insertion of a propylene monomer, as measured by ¹³C NMR, is        not more than 0.05%.

U.S. Pat. No. 5,391,629 suggests block and tapered copolymers ofethylene with an α-olefin. The copolymers are made by a process ofsequentially contacting ethylene with an α-olefin monomer in thepresence of an activated cyclopentadienyl catalyst system.

EP 0 374 695 suggests ethylene-propylene copolymers and a process forpreparing them. The copolymers have a reactivity ratio product, r₁r₂,between 0.5 and 1.5 and an isotactic index greater than 0 percent. Thecopolymers are produced in the presence of a homogeneous chiral catalystand an alumoxane co-catalyst.

There is a commercial need therefore for an ethylene propylene copolymerthat will show a melting point and an excellent balance of elasticity,flexural modulus and tensile strength. It would further be desirable ifsuch polymers could be produced at higher polymerization temperatures.

It is known that temperature affects the polymerization involving thestereo regular polymerization of alpha-olefins, in particular propylene.Under similar polymerization conditions the increase in thepolymerization temperatures leads to both a drop in molecular weight aswell as a loss in the tacticity of the alpha olefin residues along thechain. This effect exists for both the homopolymerization of the1-olefins as well as copolymerization of 1-olefins with ethylene, orother alpha-olefins. These changes in the characteristic of the polymerare detrimental to certain end uses of the polyolefin. However, thereare commercial incentives in raising the polymerization temperaturesince this improves the throughput of the polymerization reactor. Thiswould necessarily lead to better economics for production for thesepolymers if physical attributes of the polymer product, such astacticity and molecular weight, could meet or exceed the properties nowachieved at lower temperatures.

SUMMARY

We have discovered that ethylene-propylene copolymers, when produced inthe presence of a metallocene catalyst and an activator, in a singlesteady state reactor, show a surprising and unexpected balance offlexural modulus, tensile strength and elasticity. Moreover, these andother properties of the copolymers show surprising differences relativeto conventional polymer blends, such as blends of isotacticpolypropylene and ethylene-propylene copolymers.

In one embodiment, the copolymer includes from a lower limit of 5% or 6%or 8% or 10% by weight to an upper limit of 20% or 25% by weightethylene-derived units, and from a lower limit of 75% or 80% by weightto an upper limit of 95% or 94% or 92% or 90% by weightpropylene-derived units, the percentages by weight based on the totalweight of propylene- and ethylene-derived units. The copolymer issubstantially free of diene-derived units.

In various embodiments, features of the copolymers include some or allof the following characteristics, where ranges from any recited upperlimit to any recited lower limit are contemplated:

(i) a melting point ranging from an upper limit of less than 110° C., orless than 90° C., or less than 80° C., or less than 70° C., to a lowerlimit of greater than 25° C., or greater than 35° C., or greater than40° C., or greater than 45° C.;

(ii) a relationship of elasticity to 500% tensile modulus such thatElasticity≦0.935M+12, orElasticity≦0.935M+6, orElasticity≦0.935M,where elasticity is in percent and M is the 500% tensile modulus inmegapascal (MPa);

(iii) a relationship of flexural modulus to 500% tensile modulus suchthatFlexural Modulus≦4.2e ^(0.27M)+50, orFlexural Modulus≦4.2e ^(0.27M)+30, orFlexural Modulus≦4.2e ^(0.27M)+10, orFlexural Modulus≦4.2e ^(0.27M)+2,where flexural modulus is in MPa and M is the 500% tensile modulus inMPa;

(iv) a heat of fusion ranging from a lower limit of greater than 1.0joule per gram (J/g), or greater than 1.5 J/g, or greater than 4.0 J/g,or greater than 6.0 J/g, or greater than 7.0 J/g, to an upper limit ofless than 125 J/g, or less than 100 J/g, or less than 75 J/g, or lessthan 60 J/g, or less than 50 J/g, or less than 40 J/g, or less than 30J/g;

(v) a triad tacticity as determined by carbon-13 nuclear magneticresonance (¹³C NMR) of greater than 75%, or greater than 80%, or greaterthan 85%, or greater than 90%;

(vi) a tacticity index m/r ranging from a lower limit of 4 or 6 to anupper limit of 8 or 10 or 12;

(vii) a proportion of inversely inserted propylene units based on 2,1insertion of propylene monomer in all propylene insertions, as measuredby ¹³C NMR, of greater than 0.5% or greater than 0.6%;

(viii) a proportion of inversely inserted propylene units based on 1,3insertion of propylene monomer in all propylene insertions, as measuredby ¹³C NMR, of greater than 0.05%, or greater than 0.06%, or greaterthan 0.07%, or greater than 0.08%, or greater than 0.085%;

(ix) an intermolecular tacticity such that at least X % by weight of thecopolymer is soluble in two adjacent temperature fractions of a thermalfractionation carried out in hexane in 8° C. increments, where X is 75,or 80, or 85, or 90, or 95, or 97, or 99;

(x) a reactivity ratio product r₁r₂ of less than 1.5, or less than 1.3,or less than 1.0, or less than 0.8;

(xi) a molecular weight distribution Mw/Mn ranging from a lower limit of1.5 or 1.8 to an upper limit of 40 or 20 or 10 or 5 or 3;

(xii) a molecular weight of from 15,000–5,000,000;

(xiii) a solid state proton nuclear magnetic resonance (¹H NMR)relaxation time of less than 18 milliseconds (ms), or less than 16 ms,or less than 14 ms, or less than 12 ms, or less than 10 ms;

(xiv) an elasticity as defined herein of less than 30%, or less than20%, or less than 10%, or less than 8%, or less than 5%; and

(xv) a 500% tensile modulus of greater than 0.5 MPa, or greater than 0.8MPa, or greater than 1.0 MPa, or greater than 2.0 MPa.

The copolymer be made in the presence of a bridged metallocene catalyst,in a single steady-state reactor. Thus, in another aspect, the presentinvention is directed to a process for producing an ethylene-propylenecopolymer having some or all of the above-recited characteristics, byreacting ethylene and propylene in a steady-state reactor under reactiveconditions and in the presence of a bridged metallocene catalyst.

In another embodiment, the invention comprises a solution polymerizationprocess for making the above described semicrystalline ethylenepropylene copolymers by using particular catalyst and activatorcombination that lead to similar molecular weights and crystallinityfrom polymerization at a higher temperature or alternatively highermolecular weight and/or crystallinity when compared to polymerizationprocesses conducted at a lower temperature using previous catalyst andactivator combinations. This embodiment involves the use of bulky,non-coordinating activators in conjunction with single sited metallocenecatalysts capable of making the polymers described above. In anotheraspect, this embodiment can additionally operate using a higherconcentration of the monomers present in the polymerization reactorduring polymerization. The combination of these two components of theinvention leads to copolymers which have both a higher molecular weightas well as a higher level of tacticity of the propylene residues. Thusthese bulky activator systems and higher monomer concentrations can beused for the polymerization of these copolymers at higher temperaturescompared to the polymerization conducted with smaller anions while stillgenerating copolymers which have similar molecular weights and isotacticpropylene crystallinity.

DESCRIPTION OF THE DRAWINGS

These and other features, aspects and advantages of embodiments of ourinvention will become better understood with reference to the followingdescription, appended claims and accompanying drawings, in which:

FIG. 1 is a plot of the natural log of crystalline intensity (by ¹H NMR)versus time in milliseconds; T_(1ρ) referred to in this description isthe slope of the line.

FIG. 2 is a plot of flexural modulus, in MPa, versus 500% tensilemodulus, in MPa.

FIG. 3 is a plot of elasticity, in percent, versus 500% tensile modulus,in MPa.

FIG. 4 is a plot of melting point (Tm) in ° C., as determined by DSC,versus percent ethylene of copolymers of the invention (trianglesymbols) and blends of isotactic polypropylene with copolymers of theinvention (diamond symbols).

FIG. 5 is a plot of heat of fusion in J/g as a function of ethylenecontent and polymerization temperature for samples prepared using theprocess of the invention and comparative samples.

FIG. 6 is a plot of the Mooney (ML127C) as a function of propylenecontent in hexane solvent in weight percent and polymerizationtemperature for the copolymers of the current invention and comparativesamples.

DESCRIPTION

We contemplate thermoplastic polymer compositions composed of a majorityof propylene with a minor amount of ethylene. These polymer compositionsinclude a linear, single homogeneous macromolecular copolymer structure.These polymers have limited crystallinity due to adjacent isotacticpropylene units and have a melting point as described below. They aregenerally devoid of any substantial intermolecular heterogeneity intacticity and comonomer composition, and are substantially free ofdiene. They are also devoid of any substantial heterogeneity inintramolecular composition distribution. In addition, thesethermoplastic polymer compositions are unexpectedly soft and elastic.

Copolymer

Monomers in the Copolymer

According to an embodiment of the present invention, the copolymerincludes from a lower limit of 5% or 6% or 8% or 10% by weightethylene-derived units to an upper limit of 20% or 25% by weightethylene-derived units. These embodiments also will includepropylene-derived units present in the copolymer in the range of from alower limit of 75% or 80% by weight to an upper limit of 95% or 94% or92% or 90% by weight. These percentages by weight are based on the totalweight of the propylene and ethylene-derived units; i.e., based on thesum of weight percent propylene-derived units and weight percentethylene-derived units being 100%. Within these ranges, these copolymersare mildly crystalline as measured by differential scanning calorimetry(DSC), and are exceptionally soft, while still retaining substantialtensile strength and elasticity. Elasticity, as defined in detailhereinbelow, is a dimensional recovery from elongation for thesecopolymers. At ethylene compositions lower than the above limits for thecopolymer, such polymers are generally crystalline, similar tocrystalline isotactic polypropylene, and while having excellent tensilestrength, they do not have the favorable softness and elasticity. Atethylene compositions higher than the above limits for the copolymercomponent, the copolymer is substantially amorphous. While such amaterial of higher ethylene composition may be soft, these compositionsare weak in tensile strength and poor in elasticity. In summary, suchcopolymers of embodiments of our invention exhibit the softness, tensilestrength and elasticity characteristic of vulcanized rubbers, withoutvulcanization.

In embodiments of the present invention, we intend that the copolymersbe substantially free of diene-derived units. Dienes are nonconjugateddiolefins which may be incorporated in polymers to facilitate chemicalcrosslinking reactions. “Substantially free of diene” is defined to beless than 1% diene, or less than 0.5% diene, or less than 0.1% diene, orless than 0.05% diene, or equal to 0%. All of these percentages are byweight in the copolymer. The presence or absence of diene can beconventionally determined by infrared techniques well known to thoseskilled in the art.

Sources of diene include diene monomer added to the polymerization ofethylene and propylene, or use of diene in catalysts. No matter thesource of such dienes, the above outlined limits on their inclusion inthe copolymer are contemplated. Conjugated diene-containing metallocenecatalysts have been suggested for the formation of copolymers ofolefins. However, polymers made from such catalysts will incorporate thediene from the catalyst, consistent with the incorporation of othermonomers in the polymerization.

Molecular Weight and Polydispersity Index

Molecular weight distribution (MWD) is a measure of the range ofmolecular weights within a given polymer sample. It is well known thatthe breadth of the MWD can be characterized by the ratios of variousmolecular weight averages, such as the ratio of the weight averagemolecular weight to the number average molecular weight, Mw/Mn, or theratio of the Z-average molecular weight to the weight average molecularweight, Mz/Mw.

Mz, Mw and Mn can be measured using gel permeation chromatography (GPC),also known as size exclusion chromatography (SEC). This techniqueutilizes an instrument containing columns packed with porous beads, anelution solvent, and detector in order to separate polymer molecules ofdifferent sizes. In a typical measurement, the GPC instrument used is aWaters chromatograph equipped with ultrastyro gel columns operated at145° C. The elution solvent used is trichlorobenzene. The columns arecalibrated using sixteen polystyrene standards of precisely knownmolecular weights. A correlation of polystyrene retention volumeobtained from the standards, to the retention volume of the polymertested yields the polymer molecular weight.

Average molecular weights M can be computed from the expression:

$M = \frac{\sum\limits_{i}{N_{i}M_{i}^{n + 1}}}{\sum\limits_{i}{N_{i}M_{i}^{n}}}$where N_(i) is the number of molecules having a molecular weight M_(i).When n=0, M is the number average molecular weight Mn. When n=1, M isthe weight average molecular weight Mw. When n=2, M is the Z-averagemolecular weight Mz. The desired MWD function (e.g., Mw/Mn or Mz/Mw) isthe ratio of the corresponding M values. Measurement of M and MWD iswell known in the art and is discussed in more detail in, for example,Slade, P. E. Ed., Polymer Molecular Weights Part II, Marcel Dekker,Inc., NY, (1975) 287–368; Rodriguez, F., Principles of Polymer Systems3rd ed., Hemisphere Pub. Corp., NY, (1989) 155–160; U.S. Pat. No.4,540,753; Verstrate et al., Macromolecules, vol. 21, (1988) 3360; andreferences cited therein.

In embodiments of our invention, a copolymer is included having a weightaverage molecular weight (Mw) of from 15,000–5,000,000, or from 20,000to 1,000,000 and a molecular weight distribution Mw/Mn (sometimesreferred to as a “polydispersity index” (PDI)) ranging from a lowerlimit of 1.5 or 1.8 to an upper limit of 40 or 20 or 10 or 5 or 3.

In the measurement of properties ascribed to polymers of embodiments ofour invention, there is a substantial absence of a secondary or tertiarypolymer or polymers to form a blend. By “substantial absence” we intendless than 10%, or less than 5%, or less than 2.5%, or less than 1%, or0%, by weight.

In another embodiment, the copolymers of the invention have a weightaverage molecular weight that can be calculated by application of thefollowing formula:Mw>6.10*P*e ^((3370/T))Wherein:

-   Mw=the weight average molecular weight-   T=the polymerization reaction temperature in degrees Kelvin-   P=the steady state propylene concentration in the polymerization    reaction zone in moles per liter    Melting Point and Crystallinity

The copolymer, according to an embodiment of our invention, has a singlemelting point. The copolymer can be a random copolymer of ethylene andpropylene having a melting point (Tm) by Differential ScanningCalorimetry (DSC) ranging from an upper limit of less than 110° C., lessthan 90° C., less than 80° C., or less than 70° C.; to a lower limit ofgreater than 25° C., or greater than 35° C., or greater than 40° C. orgreater than 45° C. FIG. 4 shows the melting point of propylene-ethylenecopolymers of the invention as a function of ethylene weight percent,i.e., weight percent of ethylene-derived units (triangle symbols). Forcomparison, the diamond symbols in FIG. 4 show the melting point ofblends of isotactic polypropylene and the inventive copolymers also as afunction of weight percent ethylene. FIG. 4 clearly shows thatcopolymers of the present invention have a lower melting point thanpropylene-ethylene copolymer/isotactic polypropylene blends having thesame weight percent ethylene.

Embodiments of our invention include copolymers having a heat of fusion,as determined by DSC, ranging from a lower limit of greater than 1.0J/g, or greater than 1.5 J/g, or greater than 4.0 J/g, or greater than6.0 J/g, or greater than 7.0 J/g, to an upper limit of less than 125J/g, or less than 100 J/g, or less than 75 J/g, or less than 60 J/g, orless than 50 J/g, or less than 40 J/g, or less than 30 J/g. Withoutwishing to be bound by theory, we believe that the copolymers ofembodiments of our invention have generally isotactic crystallizablepropylene sequences, and the above heats of fusion are believed to bedue to the melting of these crystalline segments.

In another embodiment, the copolymers of the invention have a heat offusion that can be calculated by application of the following formula:H _(f)>311*(E−18.5)² /TWherein:

-   H_(f)=the heat of fusion, measured as described below-   E=the ethylene content (meaning units derived from ethylene) of the    copolymer, measured as described below; and-   T=the polymerization reaction temperature in degrees Kelvin.    Tacticity Index

The tacticity index, expressed herein as “m/r”, is determined by ¹³Cnuclear magnetic resonance (NMR). The tacticity index m/r is calculatedas defined in H. N. Cheng, Macromolecules, 17, 1950 (1984). Thedesignation “m” or “r” describes the stereochemistry of pairs ofcontiguous propylene groups, “m” referring to meso and “r” to racemic.An m/r ratio of 1.0 generally describes a syndiotactic polymer, and anm/r ratio of 2.0 an atactic material. An isotactic materialtheoretically may have a ratio approaching infinity, and many by-productatactic polymers have sufficient isotactic content to result in ratiosof greater than 50. Copolymers of embodiments of our invention can havea tacticity index m/r ranging from a lower limit of 4 or 6 to an upperlimit of 8 or 10 or 12.

Triad Tacticity

An ancillary procedure for the description of the tacticity of thepropylene units of embodiments of the current invention is the use oftriad tacticity. The triad tacticity of a polymer is the relativetacticity of a sequence of three adjacent propylene units, a chainconsisting of head to tail bonds, expressed as a binary combination of mand r sequences. It is usually expressed for copolymers of the presentinvention as the ratio of the number of units of the specified tacticityto all of the propylene triads in the copolymer.

The triad tacticity (mm fraction) of a propylene copolymer can bedetermined from a ¹³C NMR spectrum of the propylene copolymer and thefollowing formula:

${{mm}\mspace{14mu}{Fraction}} = \frac{{PPP}({mm})}{{{PPP}({mm})} + {{PPP}({mr})} + {{PPP}({rr})}}$where PPP(mm), PPP(mr) and PPP(rr) denote peak areas derived from themethyl groups of the second units in the following three propylene unitchains consisting of head-to-tail bonds:

The ¹³C NMR spectrum of the propylene copolymer is measured as describedin U.S. Pat. No. 5,504,172. The spectrum relating to the methyl carbonregion (19–23 parts per million (ppm)) can be divided into a firstregion (21.2–21.9 ppm), a second region (20.3–21.0 ppm) and a thirdregion (19.5–20.3 ppm). Each peak in the spectrum was assigned withreference to an article in the journal Polymer, Volume 30 (1989), page1350.

In the first region, the methyl group of the second unit in the threepropylene unit chain represented by PPP (mm) resonates.

In the second region, the methyl group of the second unit in the threepropylene unit chain represented by PPP (mr) resonates, and the methylgroup (PPE-methyl group) of a propylene unit whose adjacent units are apropylene unit and an ethylene unit resonates (in the vicinity of 20.7ppm).

In the third region, the methyl group of the second unit in the threepropylene unit chain represented by PPP (rr) resonates, and the methylgroup (EPE-methyl group) of a propylene unit whose adjacent units areethylene units resonates (in the vicinity of 19.8 ppm).

Calculation of the Triad Tacticity and Errors in Propylene Insertion

The calculation of the triad tacticity is outlined in the techniquesshown in U.S. Pat. No. 5,504,172. Subtraction of the peak areas for theerror in propylene insertions (both 2,1 and 1,3) from peak areas fromthe total peak areas of the second region and the third region, the peakareas based on the 3 propylene units-chains (PPP(mr) and PPP(rr))consisting of head-to-tail bonds can be obtained. Thus, the peak areasof PPP(mm), PPP(mr) and PPP(rr) can be evaluated, and hence the triadtacticity of the propylene unit chain consisting of head-to-tail bondscan be determined.

The propylene copolymers of embodiments of our invention have a triadtacticity of three propylene units, as measured by ¹³C NMR, of greaterthan 75%, or greater than 80%, or greater than 82%, or greater than 85%,or greater than 90%.

Stereo- and Regio- errors in Insertion of Propylene: 2,1 and 1,3Insertions

The insertion of propylene can occur to a small extent by either 2,1(tail to tail) or 1,3 insertions (end to end). Examples of 2,1 insertionare shown in structures 1 and 2 below.

where n≧2.

A peak of the carbon A and a peak of the carbon A′ appear in the secondregion. A peak of the carbon B and a peak of the carbon B′ appear in thethird region, as described above. Among the peaks which appear in thefirst to third regions, peaks which are not based on the 3 propyleneunit chain consisting of head-to-tail bonds are peaks based on thePPE-methyl group, the EPE-methyl group, the carbon A, the carbon A′, thecarbon B, and the carbon B′.

The peak area based on the PPE-methyl group can be evaluated by the peakarea of the PPE-methine group (resonance in the vicinity of 30.8 ppm),and the peak area based on the EPE-methyl group can be evaluated by thepeak area of the EPE-methine group (resonance in the vicinity of 33.1ppm). The peak area based on the carbon A can be evaluated by twice asmuch as the peak area of the methine carbon (resonance in the vicinityof 33.9 ppm) to which the methyl group of the carbon B is directlybonded; and the peak area based on the carbon A′ can be evaluated by thepeak area of the adjacent methine carbon (resonance in the vicinity of33.6 ppm) of the methyl group of the carbon B′. The peak area based onthe carbon B can be evaluated by the peak area of the adjacent methinecarbon (resonance in the vicinity of 33.9 ppm); and the peak area basedon the carbon B′ can be also evaluated by the adjacent methine carbon(resonance in the vicinity of 33.6 ppm).

By subtracting these peak areas from the total peak areas of the secondregion and the third region, the peak areas based on the three propyleneunit chains (PPP(mr) and PPP(rr)) consisting of head-to-tail bonds canbe obtained. Thus, the peak areas of PPP(mm), PPP(mr) and PPP(rr) can beevaluated, and the triad tacticity of the propylene unit chainconsisting of head-to-tail bonds can be determined.

The proportion of the 2,1-insertions to all of the propylene insertionsin a propylene elastomer was calculated by the following formula withreference to article in the journal Polymer, vol. 30 (1989), p.1350.

${{Proportion}\mspace{14mu}{of}\mspace{14mu}{inversely}\mspace{14mu}{inserted}\mspace{14mu}{unit}\mspace{14mu}{based}\mspace{14mu}{on}\mspace{14mu} 2},{{1\text{-}{insertion}\mspace{14mu}(\%)} = {\frac{{0.25I\;{{\alpha\beta}\left( {{structure}(i)} \right)}} + {0.5I\;{{\alpha\beta}\left( {{structure}({ii})} \right)}}}{{I\;{\alpha\alpha}} + {I\;{{\alpha\beta}\left( {{structure}({ii})} \right)}} + {0.5\left( {{I\;{\alpha\gamma}} + {I\;{{\alpha\beta}\left( {{structure}(i)} \right)}} + {I\;{\alpha\delta}}} \right)}} \times 100}}$

Naming of the peaks in the above formula was made in accordance with amethod by Carman, et al. in the journal Rubber Chemistry and Technology,volume 44 (1971), page 781, where I_(αδ) denotes a peak area of the αδ⁺secondary carbon peak. It is difficult to separate the peak area of Iαβ(structure (i)) from Iαβ (structure (ii)) because of overlapping of thepeaks. Carbon peaks having the corresponding areas can be substitutedtherefor.

The measurement of the 1,3 insertion requires the measurement of the βγpeak. Two structures can contribute to the βγ peak: (1) a 1,3 insertionof a propylene monomer; and (2) from a 2,1-insertion of a propylenemonomer followed by two ethylene monomers. This peak is described as the1.3 insertion peak and we use the procedure described in U.S. Pat. No.5,504,172, which describes this βγ peak and understand it to represent asequence of four methylene units. The proportion (%) of the amount ofthese errors was determined by dividing the area of the βγ peak(resonance in the vicinity of 27.4 ppm) by the sum of all the methylgroup peaks and ½ of the area of the βγ peak, and then multiplying theresulting value by 100. If an α-olefin of three or more carbon atoms ispolymerized using an olefin polymerization catalyst, a number ofinversely inserted monomer units are present in the molecules of theresultant olefin polymer. In polyolefins prepared by polymerization ofα-olefins of three or more carbon atoms in the presence of a chiralmetallocene catalyst, 2,1-insertion or 1,3-insertion takes place inaddition to the usual 1,2-insertion, such that inversely inserted unitssuch as a 2,1-insertion or a 1,3-insertion are formed in the olefinpolymer molecule (see, Macromolecular Chemistry Rapid Communication,Volume 8, page 305 (1987), by K. Soga, T. Shiono, S. Takemura and W.Kaminski).

The proportion of inversely inserted propylene units of embodiments ofour invention, based on the 2,1-insertion of a propylene monomer in allpropylene insertions, as measured by ¹³C NMR, is greater than 0.5%, orgreater than 0.6%.

The proportion of inversely inserted propylene units of embodiments ofour invention, based on the 1,3-insertion of a propylene monomer, asmeasured by ¹³C NMR, is greater than 0.05%, or greater than 0.06%, orgreater than 0.07%, or greater than 0.08%, or greater than 0.085percent.

Molecular Structure

Homogeneous distribution

Homogeneous distribution is defined as a statistically insignificantintermolecular difference of both in the composition of the copolymerand in the tacticity of the polymerized propylene. For a copolymer tohave a homogeneous distribution it must meet the requirement of twoindependent tests: (i) intermolecular distribution of tacticity; and(ii) intermolecular distribution of composition, which are describedbelow. These tests are a measure of the statistically insignificantintermolecular differences of tacticity of the polymerized propylene andthe composition of the copolymer, respectively.

Intermolecular Distribution of Tacticity

The copolymer of embodiments of our invention has a statisticallyinsignificant intermolecular difference of tacticity of polymerizedpropylene between different chains (intermolecularly.). This isdetermined by thermal fractionation by controlled dissolution generallyin a single solvent, at a series of slowly elevated temperatures. Atypical solvent is a saturated hydrocarbon such as hexane or heptane.These controlled dissolution procedures are commonly used to separatesimilar polymers of different crystallinity due to differences inisotactic propylene sequences, as shown in the article inMacromolecules, Vol. 26, p 2064 (1993). For the copolymers ofembodiments of our invention where the tacticity of the propylene unitsdetermines the extent of crystallinity, we expected this fractionationprocedure will separate the molecules according to tacticity of theincorporated propylene. This procedure is described below.

In embodiments of our invention, at least 75% by weight, or at least 80%by weight, or at least 85% by weight, or at least 90% by weight, or atleast 95% by weight, or at least 97% by weight, or at least 99% byweight of the copolymer is soluble in a single temperature fraction, orin two adjacent temperature fractions, with the balance of the copolymerin immediately preceding or succeeding temperature fractions. Thesepercentages are fractions, for instance in hexane, beginning at 23° C.and the subsequent fractions are in approximately 8° C. increments above23° C. Meeting such a fractionation requirement means that a polymer hasstatistically insignificant intermolecular differences of tacticity ofthe polymerized propylene.

Fractionations have been done where boiling pentane, hexane, heptane andeven di-ethyl ether are used for the fractionation. In such boilingsolvent fractionations, polymers of embodiments of our invention will betotally soluble in each of the solvents, offering no analyticalinformation. For this reason, we have chosen to do the fractionation asreferred to above and as detailed herein, to find a point within thesetraditional fractionations to more fully describe our polymer and thesurprising and unexpected insignificant intermolecular differences oftacticity of the polymerized propylene.

Intermolecular Distribution of Composition

The copolymer of embodiments of our invention has statisticallyinsignificant intermolecular differences of composition, which is theratio of propylene to ethylene between different chains(intermolecular). This compositional analysis is by infraredspectroscopy of the fractions of the polymer obtained by the controlledthermal dissolution procedure described above.

A measure of the statistically insignificant intermolecular differencesof composition, each of these fractions has a composition (wt. %ethylene content) with a difference of less than 1.5 wt. % (absolute) orless than 1.0 wt. % (absolute), or less than 0.8 wt. % (absolute) of theaverage wt. % ethylene content of the whole copolymer. Meeting such afractionation requirement means that a polymer has statisticallyinsignificant intermolecular differences of composition, which is theratio of propylene to ethylene.

Uniformity

Uniformity is defined to be a statistically insignificant intramoleculardifference of both the composition of the copolymer and in the tacticityof the polymerized propylene. For a copolymer to be uniform it must meetthe requirement of two independent tests: (i) intramoleculardistribution of tacticity; and (ii) intramolecular distribution ofcomposition, which are described below. These tests are a measure of thestatistically insignificant intramolecular differences of tacticity ofthe polymerized propylene and the composition of the copolymer,respectively.

Intramolecular Distribution of Composition

The copolymer of embodiments of our invention has statisticallyinsignificant intramolecular differences of composition, which is theratio of propylene to ethylene along the segments of the same chain(intramolecular). This compositional analysis is inferred from theprocess used for the synthesis of these copolymers as well as theresults of the sequence distribution analysis of the copolymer, formolecular weights in the range of from 15,000–5,000,000 or20,000–1,000,000.

Process

The polymerization process is a single stage, steady state,polymerization conducted in a well-mixed continuous feed polymerizationreactor. The polymerization can be conducted in solution, although otherpolymerization procedures such as gas phase or slurry polymerization,which fulfil the requirements of single stage polymerization andcontinuous feed reactors, are contemplated.

The process can be described as a continuous, non-batch process that, inits steady state operation, is exemplified by removal of amounts ofpolymer made per unit time, being substantially equal to the amount ofpolymer withdrawn from the reaction vessel per unit time. By“substantially equal” we intend that these amounts, polymer made perunit time, and polymer withdrawn per unit time, are in ratios of one toother, of from 0.9:1; or 0.95:1; or 0.97:1; or 1:1. In such a reactor,there will be a substantially homogeneous monomer distribution. At thesame time, the polymerization is accomplished in substantially singlestep or stage or in a single reactor, contrasted to multistage ormultiple reactors (two or more). These conditions exist forsubstantially all of the time the copolymer is produced.

Monomer Sequence Distribution

One method to describe the molecular features of an ethylene-propylenecopolymer is monomer sequence distribution. Starting with a polymerhaving a known average composition, the monomer sequence distributioncan be determined using spectroscopic analysis. Carbon 13 nuclearmagnetic resonance spectroscopy (¹³C NMR) can be used for this purpose,and can be used to establish diad and triad distribution via theintegration of spectral peaks. (If ¹³C NMR is not used for thisanalysis, substantially lower r₁r₂ products are normally obtained.) Thereactivity ratio product is described more fully in Textbook of PolymerChemistry, F. W. Billmeyer, Jr., Interscience Publishers, New York, p.221 et seq. (1957).

The reactivity ratio product r₁r₂, where r₁ is the reactivity ofethylene and r₂ is the reactivity of propylene, can be calculated fromthe measured diad distribution (PP, EE, EP and PE in this nomenclature)by the application of the following formulae:r ₁ r ₂=4(EE)(PP)/(EP)²r ₁ =K ₁₁ /K ₁₂=[2(EE)/EP]Xr ₂ =K ₂₂ /K ₂₁=[2(PP)/(EP)]XP=(PP)+(EP/2)E=(EE)+(EP/2)whereMol % E=[(E)/(E+P)]*100

X=E/P in reactor;

K₁₁ and K₁₂ are kinetic insertion constants for ethylene; and

K₂₁ and K₂₂ are kinetic insertion constants for propylene.

As is known to those skilled in the art, a reactivity ratio product r₁r₂of 0 can define an “alternating” copolymer, and a reactivity ratioproduct of 1 is said to define a “statistically random” copolymer. Inother words, a copolymer having a reactivity ratio product r₁r₂ ofbetween 0.6 and 1.5 is generally said to be random (in stricttheoretical terms, generally only a copolymer having a reactivity ratioproduct r₁r₂ greater than 1.5 contains relatively long homopolymersequences and is said to be “blocky”). The copolymer of our inventionwill have a reactivity ratio product r₁r₂ of less than 1.5, or less than1.3, or less than 1.0, or less than 0.8. The substantially uniformdistribution of comonomer within polymer chains of embodiments of ourinvention generally precludes the possibility of significant amounts ofpropylene units or sequences within the polymer chain for the molecularweights (weight average) disclosed herein.

Intramolecular Distribution of Tacticity

The copolymer of embodiments of our invention has statisticallyinsignificant intramolecular differences of tacticity, which is due toisotactic orientation of the propylene units along the segments of thesame chain (intramolecular). This compositional analysis is inferredfrom the detailed analysis of the differential scanning calorimetry,electron microscopy and relaxation measurement (T_(1ρ)). In the presenceof significant intramolecular differences in tacticity, we would form‘stereoblock’ structures, where the number of isotactic propyleneresidues adjacent to one another is much greater than statistical.Further, the melting point of these polymers depends on thecrystallinity, since the more blocky polymers should have a highermelting point as well as depressed solubility in room temperaturesolvents.

T_(1ρ): Solid-state ¹H NMR T_(1ρ) Relaxation Time

The principle of solid state proton NMR relaxation time (¹H NMR T_(1ρ))and its relationship with polymer morphology have been discussed inMacromolecules 32 (1999), 1611. The experimental T_(1ρ) relaxation dataof embodiments of the current invention, and polypropylene (PP)homopolymer (control sample) are shown in FIG. 1, which plots thenatural log of the crystalline intensity versus time; the experimentalprocedure for collecting these data is described below. To fit the datawith single exponential function, linear regression was performed on the1n(I) vs. t data, where I is the intensity of the crystalline signal.Then, the quality of the fit, R², is calculated. The R² for a perfectlinear correlation is 1.0. The R² for polypropylene (control) and acopolymer of the current invention (shown in FIG. 1) are 0.9945 and0.9967, respectively. Therefore, the T_(1ρ) relaxation for bothpolypropylene homopolymer and a copolymer of the current invention canbe well fitted by a single-exponential. From the fit, the T_(1ρ) ofpolypropylene and a copolymer of the present invention, are calculatedas 25 milliseconds (ms) and 8.7 ms, respectively. The large differencein the T_(1ρ) is reflective of their difference in morphology.

The hypothetical polypropylene-like regions would have T_(1ρ) relaxationsimilar to that in polypropylene homopolymer. As a result, should suchregions exist in embodiments of the invention, the T_(1ρ) relaxationwould contain a component that has a T_(1ρ) relaxation timecharacteristic of polypropylene homopolymer (i.e., T_(1ρ)=25 ms). Asseen in FIG. 1, the T_(1ρ) relaxation of the current invention can onlybe well fitted by a single exponential. Incorporation of a componentwhose T_(1ρ)=25 ms would deteriorate the fit. This demonstrates that thepolymers of the current invention do not contain long continuousisotactic propylene units. In embodiments of our invention, the T_(1ρ),relaxation time can be less than 18 ms, or less than 16 ms, or less than14 ms, or less than 12 ms, or less than 10 ms.

T_(1ρ) Measurement

The experiments are performed on a Bruker DSX-500 Nuclear MagneticResonance (NMR) spectrometer, with a ¹H frequency of 500.13 MHz and ¹³Cfrequency of 125.75 MHz. The pulse sequence was a 90° (¹H) pulsefollowed by spin lock and cross polarization (“CP”; time=0.1 ms). A spinlock field strength of γB₁=2π*60 kHz is used. After the spin lock, themagnetization is transferred to ¹³C by CP and then the signal isdetected. The crystalline methine signal at 26.7 ppm is recorded andnormalized and its natural logarithm (Ln) is plotted against spin locktime in FIG. 1. Measurements were made on a polypropylene homopolymersample, and on a polymer of the present invention, labeled “Sample 4”and described in the Examples below. Table 1 presents the data.

TABLE 1 Time (ms) Ln(I) (sample 4) Ln(I) (PP) 0.02 0 0 0.5 −0.11394−0.02496 1 −0.18772 −0.04733 2 −0.32424 −0.09871 5 −0.71649 −0.24692 10−1.27022 −0.44715 20 −2.34181 −0.79526Catalysts and Activators for Copolymer ProductionCatalysts

A typical isotactic polymerization process consists of a polymerizationin the presence of a catalyst including a bis(cyclopentadienyl) metalcompound and either (1) a non-coordinating compatible anion activator,or (2) an alumoxane activator. According to one embodiment of theinvention, this process comprises the steps of contacting ethylene andpropylene with a catalyst in a suitable polymerization diluent, thecatalyst including, in one embodiment, a chiral metallocene compound,e.g., a bis(cyclopentadienyl) metal compound as described in U.S. Pat.No. 5,198,401, and an activator. U.S. Pat. No. 5,391,629 also describescatalysts useful to produce the copolymers of our invention.

The catalyst system described below useful for making the copolymers ofembodiments of our invention, is a metallocene with a non-coordinatinganion (NCA) activator, and optionally a scavenging compound.Polymerization is conducted in a solution, slurry or gas phase. Thepolymerization can be performed in a single reactor process. A slurry orsolution polymerization process can utilize sub- or superatmosphericpressures and temperatures in the range of from −25° C. to 110° C. In aslurry polymerization, a suspension of solid, particulate polymer isformed in a liquid polymerization medium to which ethylene, propylene,hydrogen and catalyst are added. In solution polymerization, the liquidmedium serves as a solvent for the polymer. The liquid employed as thepolymerization medium can be an alkane or a cycloalkane, such as butane,pentane, hexane, or cylclohexane, or an aromatic hydrocarbon, such astoluene, ethylbenzene or xylene. For slurry polymerization, liquidmonomer can also be used. The medium employed should be liquid under theconditions of the polymerization and relatively inert. Hexane or toluenecan be employed for solution polymerization. Gas phase polymerizationprocesses are described in U.S. Pat. Nos. 4,543,399, 4,588,790,5,028,670, for example. The catalyst can be supported on any suitableparticulate material or porous carrier, such as polymeric supports orinorganic oxides, such as, for example silica, alumina or both. Methodsof supporting metallocene catalysts are described in U.S. Pat. Nos.4,808,561, 4,897,455, 4,937,301, 4,937,217, 4,912,075, 5,008,228,5,086,025, 5,147,949, and 5,238,892.

Propylene and ethylene are the monomers that can be used to make thecopolymers of embodiments of our invention, but optionally, ethylene canbe replaced or added to in such polymers with a C4 to C20 α-olefin, suchas, for example, 1-butene, 4-methyl-1-pentene, 1-hexene or 1-octene.

Metallocene

The terms “metallocene” and “metallocene catalyst precursor” are termsknown in the art to mean compounds possessing a Group 4, 5, or 6transition metal M, with a cyclopentadienyl (Cp) ligand or ligands whichmay be substituted, at least one non-cyclopentadienyl-derived ligand X,and zero or one heteroatom-containing ligand Y, the ligands beingcoordinated to M and corresponding in number to the valence thereof. Themetallocene catalyst precursors generally require activation with asuitable co-catalyst (sometimes referred to as an activator) in order toyield an active metallocene catalyst, i.e., an organometallic complexwith a vacant coordination site that can coordinate, insert, andpolymerize olefins.

Preferred metallocenes are cyclopentadienyl complexes which have two Cpring systems as ligands. The Cp ligands preferably form a bent sandwichcomplex with the metal, and are preferably locked into a rigidconfiguration through a bridging group. These cyclopentadienyl complexeshave the general formula:(Cp¹R¹ _(m))R³ _(n)(Cp²R² _(p))MX_(q)wherein Cp¹ and Cp² are preferably the same; R¹ and R² are each,independently, a halogen or a hydrocarbyl, halocarbyl,hydrocarbyl-substituted organometalloid or halocarbyl-substitutedorganometalloid group containing up to 20 carbon atoms; m is preferably1 to 5; p is preferably 1 to 5; preferably two R¹ and/or R² substituentson adjacent carbon atoms of the cyclopentadienyl ring associatedtherewith can be joined together to form a ring containing from 4 to 20carbon atoms; R³ is a bridging group; n is the number of atoms in thedirect chain between the two ligands and is preferably 1 to 8, mostpreferably 1 to 3; M is a transition metal having a valence of from 3 to6, preferably from group 4, 5, or 6 of the periodic table of theelements, and is preferably in its highest oxidation state; each X is anon-cyclopentadienyl ligand and is, independently, a hydrocarbyl,oxyhydrocarbyl, halocarbyl, hydrocarbyl-substituted organometalloid,oxyhydrocarbyl-substituted organometalloid or halocarbyl-substitutedorganometalloid group containing up to 20 carbon atoms; and q is equalto the valence of M minus 2.

Numerous examples of the biscyclopentadienyl metallocenes describedabove for the invention are disclosed in U.S. Pat. Nos. 5,324,800;5,198,401; 5,278,119; 5,387,568; 5,120,867; 5,017,714; 4,871,705;4,542,199; 4,752,597; 5,132,262; 5,391,629; 5,243,001; 5,278,264;5,296,434; and 5,304,614.

Illustrative, but not limiting examples of preferred biscyclopentadienylmetallocenes of the type described above are the racemic isomers of:

μ-(CH₃)₂Si(indenyl)₂M(Cl)₂,

μ-(CH₃)₂Si(indenyl)₂M(CH₃)₂,

μ-(CH₃)₂Si(tetrahydroindenyl)₂M(Cl)₂,

μ-(CH₃)₂Si(tetrahydroindenyl)₂M(CH₃)₂,

μ-(CH₃)₂Si(indenyl)₂M(CH₂CH₃)₂, and

μ-(C₆H₅)₂C(indenyl)₂M(CH₃)₂,

wherein M is Zr, Hf, or Ti.

Non-coordinating Anions

As already mentioned, the metallocene or precursor are activated with anon-coordinating anion. The term “non-coordinating anion” means an anionwhich either does not coordinate to the transition metal cation or whichis only weakly coordinated to the cation, thereby remaining sufficientlylabile to be displaced by a neutral Lewis base. “Compatible”non-coordinating anions are those which are not degraded to neutralitywhen the initially formed complex decomposes. Further, the anion willnot transfer an anionic substituent or fragment to the cation so as tocause it to form a neutral four coordinate metallocene compound and aneutral by-product from the anion. Non-coordinating anions useful inaccordance with this invention are those which are compatible, stabilizethe metallocene cation in the sense of balancing its ionic charge, yetretain sufficient lability to permit displacement by an ethylenically oracetylenically unsaturated monomer during polymerization. Additionally,the anions useful in this invention may be large or bulky in the senseof sufficient molecular size to largely inhibit or preventneutralization of the metallocene cation by Lewis bases other than thepolymerizable monomers that may be present in the polymerizationprocess. Typically the anion will have a molecular size of greater thanor equal to 4 angstroms.

Descriptions of ionic catalysts for coordination polymerizationincluding metallocene cations activated by non-coordinating anionsappear in the early work in EP-A-0 277 003, EP-A-0 277 004, U.S. Pat.Nos. 5,198,401 and 5,278,119, and WO 92/00333. These references suggesta method of preparation wherein metallocenes (bis Cp and mono Cp) areprotonated by anionic precursors such that an alkyl/hydride group isabstracted from a transition metal to make it both cationic andcharge-balanced by the non-coordinating anion. The use of ionizing ioniccompounds not containing an active proton but capable of producing boththe active metallocene cation and a non-coordinating anion is alsoknown. See, EP-A-0 426 637, EP-A-0 573 403 and U.S. Pat. No. 5,387,568.Reactive cations other than Bronsted acids capable of ionizing themetallocene compounds include ferrocenium, triphenylcarbonium, andtriethylsilylium cations. Any metal or metalloid capable of forming acoordination complex which is resistant to degradation by water (orother Bronsted or Lewis acids) may be used or contained in the anion ofthe second activator compound. Suitable metals include, but are notlimited to, aluminum, gold, platinum and the like. Suitable metalloidsinclude, but are not limited to, boron, phosphorus, silicon and thelike.

An additional method of making the ionic catalysts uses ionizing anionicpre-cursors which are initially neutral Lewis acids but form the cationand anion upon ionizing reaction with the metallocene compounds. Forexample tris(pentafluorophenyl) boron acts to abstract an alkyl, hydrideor silyl ligand to yield a metallocene cation and stabilizingnon-coordinating anion; see EP-A-0 427 697 and EP-A-0 520 732. Ioniccatalysts for addition polymerization can also be prepared by oxidationof the metal centers of transition metal compounds by anionic precursorscontaining metallic oxidizing groups along with the anion groups; seeEP-A-0 495 375.

Illustrative, but not limiting, examples of suitable activators capableof ionic cationization of the metallocene compounds of the invention,and consequent stabilization with a resulting non-coordinating anion,include:

trialkyl-substituted ammonium salts such as:

-   triethylammonium tetraphenylborate;-   tripropylammonium tetraphenylborate;-   tri(n-butyl)ammonium tetraphenylborate;-   trimethylammonium tetrakis(p-tolyl)borate;-   trimethylammonium tetrakis(o-tolyl)borate;-   tributylammonium tetrakis(pentafluorophenyl)borate;-   tripropylammonium tetrakis(o,p-dimethylphenyl)borate;-   tributylammonium tetrakis(m,m-dimethylphenyl)borate;-   tributylammonium tetrakis(p-trifluoromethylphenyl)borate;-   tributylammonium tetrakis(pentafluorophenyl)borate;-   tri(n-butyl)ammonium tetrakis(o-tolyl)borate and the like;

N,N-dialkyl anilinium salts such as:

-   N,N-dimethylanilinium tetrakis(pentafluorophenyl)borate;-   N,N-dimethylanilinium tetrakis(heptafluoronaphthyl)borate;-   N,N-dimethylanilinium tetrakis(perfluoro-4-biphenyl)borate;-   N,N-dimethylanilinium tetraphenylborate;-   N,N-diethylanilinium tetraphenylborate;-   N,N-2,4,6-pentamethylanilinium tetraphenylborate and the like;

dialkyl ammonium salts such as:

-   di-(isopropyl)ammonium tetrakis(pentafluorophenyl)borate;-   dicyclohexylammonium tetraphenylborate and the like; and

triaryl phosphonium salts such as:

-   triphenylphosphonium tetraphenylborate;-   tri(methylphenyl)phosphonium tetraphenylborate;-   tri(dimethylphenyl)phosphonium tetraphenylborate and the like.

Further examples of suitable anionic precursors include those comprisinga stable carbonium ion, and a compatible non-coordinating anion. Theseinclude:

-   tropyllium tetrakis(pentafluorophenyl)borate;-   triphenylmethylium tetrakis(pentafluorophenyl)borate;-   benzene (diazonium) tetrakis(pentafluorophenyl)borate;-   tropyllium phenyltris(pentafluorophenyl)borate;-   triphenylmethylium phenyl-(trispentafluorophenyl)borate;-   benzene (diazonium) phenyl-tris(pentafluorophenyl)borate;-   tropyllium tetrakis(2,3,5,6-tetrafluorophenyl)borate;-   triphenylmethylium tetrakis(2,3,5,6-tetrafluorophenyl)borate;-   benzene (diazonium) tetrakis(3,4,5-trifluorophenyl)borate;-   tropyllium tetrakis(3,4,5-trifluorophenyl)borate;-   benzene (diazonium) tetrakis(3,4,5-trifluorophenyl)borate;-   tropyllium tetrakis(3,4,5-trifluorophenyl)aluminate;-   triphenylmethylium tetrakis(3,4,5-trifluorophenyl)aluminate;-   benzene (diazonium) tetrakis(3,4,5-trifluorophenyl)aluminate;-   tropyllium tetrakis(1,2,2-trifluoroethenyl)borate;-   triphenylmethylium tetrakis(1,2,2-trifluoroethenyl)borate;-   benzene (diazonium) tetrakis(1,2,2-trifluoroethenyl)borate;-   tropyllium tetrakis(2,3,4,5-tetrafluorophenyl)borate;-   triphenylmethylium tetrakis(2,3,4,5-tetrafluorophenyl)borate;-   benzene (diazonium) tetrakis(2,3,4,5-tetrafluorophenyl)borate, and    the like.

A catalyst system of μ-(CH₃)₂Si(indenyl)₂Hf(CH₃)₂ with a cocatalyst ofN,N-dimethylanilinium tetrakis(pentafluorophenyl)borate, can be used.

In a preferred embodiment, the activating cocatalyst, precursor ioniccompounds comprise anionic Group 13 element complexes having fourhalogenated aromatic ligands typically bulkier than substitutedtetraphenyl boron compounds of the exemplified in the identified priorart. These invention aromatic ligands consist of polycyclic aromatichydrocarbons and aromatic ring assemblies in which two or more rings (orfused ring systems) are joined directly to one another or together.These ligands, which may be the same or different, are covalently bondeddirectly to the metaumetalloid center. In a preferred embodiment thearyl groups of said halogenated tetraaryl Group 13 element anioniccomplex comprise at least one fused polycyclic aromatic hydrocarbon orpendant aromatic ring. Indenyl, napthyl, anthracyl, heptalenyl andbiphenyl ligands are exemplary. The number of fused aromatic rings isunimportant so long as the ring junctions and especially the atom chosenas the point of connection to the Group 13 element center permit anessentially tetrahedral structure. Thus, for example, suitable ligandsinclude those illustrated below, the open bond being to the Group 13atom. See also the polycyclic compound examples in the literature foradditional ligand selection, e.g., Nomenclature of Organic Compounds,Chs. 4–5 (ACS, 1974).

The choice of ligand connection point is particularly important.Substituents or ring junctions ortho to the ligand connection pointpresent such steric bulk that adoption of an essentially tetrahedralgeometry is largely precluded. Examples of undesirable connection pointsare depicted below.

Suitable mixed-ligand Group 13 complexes can include fused rings or ringassemblies with ortho-substituents, or ring junctions, so long as thoseligands do not exceed two in number. Thus Group 13 anions with one ortwo hindered fused ring aromatics with three or two unhindered ligands,where hindered aromatics are those having ortho substituents or ringjunctions (illustration II) and unhindered are those without(illustration I), will typically be suitable. Tris(perfluorophenyl)(perfluoroanthracyl)borate is an illustrative complex. In this complexthe anthracyl ligand is a hindered fused ring having ortho-substituentsbut its use with three unhindred phenyl ligands allows the complex toadopt a tetrahedral structure. Thus, generically speaking, the Group 13complexes useful in a accordance with the invention will typicallyconform to the following formula:[M(A)_(4−n)(B)_(n)]⁺where, M is a Group 13 element, A is an unhindered ligand as describedabove, B is a hindered ligand as described above, and n=1,2.

For both fused aromatic rings and aromatic ring assemblies, halogenationis highly preferred so as to allow for increased charge dispersion thatcontributes along with steric bulk as independent features decreasingthe likelihood of ligand abstraction by the strongly Lewis acidicmetallocene cation formed in the catalyst activation. Additionally,halogenation inhibits reaction of the hafnium cation with any remainingcarbon-hydrogen bonds of the aromatic rings, and perhalogenationprecludes such potential undesirable reactions. Thus it is preferredthat at least one third of hydrogen atoms on carbon atoms of the arylligands can be replaced by halogen atoms, and more preferred that thearyl ligands be perhalogenated. Fluorine is the most preferred halogen.

Means of preparing ionic catalyst systems comprising catalyticallyactive cations of the hafnium compounds and suitable noncoordinatinganions are conventionally known, see for example U.S. Pat. No.5,198,401, WO 92/00333, and WO 97/22639. Typically the methods compriseobtaining from commercial sources or synthesizing the selectedtransition metal compounds comprising an abstractable ligand, e.g.,hydride, alkyl or silyl group, and contacting them with anoncoordinating anion source or precursor compound in a suitablesolvent. The anion precursor compound abstracts a univalent hydride,alkyl or silyl ligand that completes the valency requirements of thepreferred hafnium metallocene compounds. The abstraction leaves thehafnocenes in a cationic state which is counterbalanced by the stable,compatible and bulky, noncoordinating anions according to the invention.

The noncoordinating anions are preferably introduced into the catalystpreparation step as ionic compounds having an essentially cationiccomplex which abstracts a non-cyclopentadienyl, labile ligand of thetransition metal compounds which upon abstraction of thenon-cyclopentadienyl ligand, leave as a by-product the noncoordinatinganion portion. Hafnium compounds having labile hydride, alkyl, or silylligands on the metal center are highly preferred for the ionic catalystsystems of this invention since known in situ alkylation processes mayresult in competing reactions and interactions that tend to interferewith the overall polymerization efficiency under high temperatureconditions in accordance with the preferred process embodiments of theinvention.

Suitable cations for precursor compounds capable of providing thenoncoordinating anions of the invention cocatalysts include those knownin the art. Such include the nitrogen-containing cations such as thosein U.S. Pat. No. 5,198,401, the carbenium, oxonium or sulfonium cationsof U.S. Pat. No. 5,387,568, metal cations, e.g., Ag⁺, the silyliumcations of WO 96/08519, and the hydrated salts of Group 1 or 2 metalcations of WO 97/22635. Each of the documents of this paragraph areincorporated by reference for purposes of U.S. patent practice.

Examples of preferred precursor salts of the noncoordinating anionscapable of ionic cationization of the metallocene compounds of theinvention, and consequent stabilization with a resulting noncoordinatinganion include trialkyl-substituted ammonium salts such astriethylammonium tetrakis(perfluoronapthyl) ortetrakis(perfluoro-4-biphenyl)boron, tripropylammoniumtetrakis(perfluoronapthyl) or tetrakis(perfluoro-4-biphenyl)boron,tri(n-butyl)ammonium tetrakis(perfluoronapthyl) ortetrakis(perfluoro-4-biphenyl)boron, trimethylammoniumtetrakis(perfluoronapthyl) or tetrakis(perfluoro-4-biphenyl)boron,trimethylammonium tetra tetrakis(perfluoronapthyl) ortetrakis(perfluoro-4-biphenyl)boron, tributylammoniumtetrakis(perfluoronapthyl) or tetrakis(perfluoro-4-biphenyl)boron,tripropylammonium tetrakis(perfluoronapthyl) ortetrakis(perfluoro-4-biphenyl), tributylammoniumtetrakis(perfluoronapthyl) or tetrakis(perfluoro-4-biphenyl)boron,tributylammonium tetrakis(perfluoronapthyl) ortetrakis(perfluoro-4-biphenyl)boron, tributylammoniumtetrakis(perfluoronapthyl) or tetrakis(perfluoro-4-biphenyl)boron,tri(n-butyl)ammonium tetrakis(perfluoronapthyl) ortetrakis(perfluoro-4-biphenyl)boron and the like; N,N-dialkyl aniliniumsalts such as N,N-dimethylanilinium tetrakis(perfluoronapthyl) ortetrakis(perfluoro-4-biphenyl)boron, N,N-diethylaniliniumtetrakis(perfluoronapthyl) or tetrakis(perfluoro-4-biphenyl)boron,N,N-2,4,6-pentamethylanilinium tetrakis(perfluoronapthyl) ortetrakis(perfluoro-4-biphenyl)boron and the like; dialkyl ammonium saltssuch as di-(isopropyl)ammonium tetrakis(perfluoronapthyl) ortetrakis(perfluoro-4-biphenyl)boron, dicyclohexylammoniumtetrakis(perfluoronapthyl) or tetrakis(perfluoro-4-biphenyl)boron andthe like; and triaryl phosphonium salts such as triphenylphosphoniumtetrakis(perfluoronapthyl) or tetrakis(perfluoro-4-biphenyl)boron,tri(methylphenyl)phosphonium tetrakis(per-fluoronapthyl) ortetrakis(perfluoro-4-biphenyl)boron, tri(dimethylphenyl)phosphoniumtetrakis(perfluoronapthyl) or tetrakis(perfluoro-4-biphenyl)boron andthe like.

Further examples of suitable anionic precursors include those comprisinga stable carbenium ion, and a compatible non-coordinating anion. Theseinclude tropillium tetrakis(perfluoronapthyl) ortetrakis(perfluoro-4-biphenyl) borate, triphenylmethyliumtetrakis(perfluoronapthyl) or tetrakis(perfluoro-4-biphenyl) borate,benzene (diazonium) tetrakis(perfluoronapthyl) ortetrakis(perfluoro4-biphenyl) borate, tropilliumtetrakis(perfluoronapthyl) or tetrakis(perfluoro-4-biphenyl)borate,triphenylmethylium tetrakis(perfluoronapthyl) ortetrakis(perfluoro-4-biphenyl)borate, benzene(diazonium)tetrakis(perfluoronapthyl) or tetrakis(perfluoro-4-biphenyl)borate,tropillium tetrakis(perfluoronapthyl) ortetrakis(perfluoro-4-biphenyl)borate, triphenylmethyliumtetrakis(perfluoronapthyl) or tetrakis(perfluoro-4-biphenyl)borate,benzene(diazonium)tetrakis(perfluoronapthyl) ortetrakis(perfluoro-4-biphenyl)borate. The essentially structurallyequivalent silylium borate or aluminate salts are similarly suitable.

In yet another embodiment, the NCA portion comprises an acetylene groupand is sometimes referred to as an “acetyl-aryl” moiety. Adistinguishing feature of invention NCAs is the presence of anacetylenic functional group bound to a Group-13 atom. The Group-13 atomalso connects to at least one fluorinated ring moiety: monofluorinatedup through perfluorinated. In addition to a first ring moiety, theGroup-13 atom has two other ligands that may also be ring moietiessimilar to or different from the first ring moiety and may bemonofluorinated to perfluorinated. The goal of fluorination is to reducethe number of abstractable hydrogen. A ligand is referred to assubstantially fluorinated when enough hydrogen has beenfluorine-replaced so that the amount of remaining abstractable hydrogenis small enough that it does not interfere with commercialpolymerization.

An exemplary invention NCA is shown below.

Tr stands for triel, which, for this disclosure, encompasses B and Al.When Tr=B, this NCA is calledtris(2′,3,3′,4,4′,5,5′,6,6′-nonafluorobiphen-2-yl)(2-perfluorophenylethyn-2-yl)borate.

The cationic portion of activators according to this embodimentpreferably has the form R₃PnH, wherein R represents an alkyl or arylmoiety; Pn represents a pnictide; N, P, or As; and H is hydrogen.Suitable R are shown below. This list does not limit the scope of theinvention; any R that allows the cationic portion to function asdescribed is within the scope of this invention. R includes, but is notlimited to, methyl, phenyl, ethyl, propyl, butyl, hexyl, octyl, nonyl,3-ethylnonyl, isopropyl, n-butyl, cyclohexyl, benzyl, trimethylsilyl,triethylsilyl, tri-n-propylsilyl, tri-isopropylsilyl,methylethylhexylsilyl, diethylnonlysilyl, triethylsilylpropyl,2,2-dimethyloctyl, triethylsilylethyl, tri-n-propylsilylhexyl,tri-isopropylsilyloctyl, and methyldiethylsilyloctyl.

Properties and Analysis of the Copolymer

Elongation and Tensile Strength

Elongation and tensile strength were measured as described below. Thecopolymers of the current invention have an elongation of greater than1000%, or greater than 1200%, or greater than 1500%.

The copolymers of the current invention have a tensile strength greaterthan 300 psi (2.1 MPa), or greater than 500 psi (3.5 MPa) or greaterthan 1000 psi (6.9 MPa).

Tensile and elongation properties are determined at 20 in/min (51cm/min) according to the procedure described in ASTM D790. The data isreported in engineering units with no correction to the stress for thelateral contraction in the specimen due to tensile elongation. Thetensile and elongation properties of embodiments of our invention areevaluated using dumbbell-shaped samples. The samples are compressionmolded at 180° C. to 200° C. for 15 minutes at a force of 15 tons (133kN) into a plaque of dimensions of 6 in×6 in (15 cm×15 cm). The cooledplaques are removed and the specimens are removed with a die. Theelasticity evaluation of the samples is conducted on an Instron 4465,made by Instron Corporation of 100 Royall Street, Canton, Mass. Thedigital data is collected in a file collected by the Series IX MaterialTesting System available from Instron Corporation and analyzed usingExcel 5, a spreadsheet program available from Microsoft Corporation ofRedmond, Wash.

Elasticity

Embodiments of our invention are elastic after tensile deformation. Theelasticity, represented by the fractional increase in the length of thesample, represented as percent of the length of the sample, is measuredaccording to the general procedure ASTM D790. During tensile elongation,the copolymer sample is stretched, and the polymer attempts to recoverits original dimensions when the stretching force is removed. Thisrecovery is not complete, and the final length of the relaxed sample isslightly longer than that of the original sample. Elasticity isrepresented by the fractional increase in the length of the sample,expressed as a percent of the length of the original un-stretchedsample.

The protocol for measuring the elasticity of the sample consists ofprestretching the deformable zone of the dumbbell, made according to theprocedure described above for the measurement of elongation and tensilestrength, which is the narrow portion of the specimen, to 200% of itsoriginal length to prestretch the sample. This is conducted at adeformation rate of 10 inches (25 cm) per minute. The sample is relaxedat the same rate to form an analytical specimen which is a prestretchedspecimen of the original sample. This slightly oriented, orprestretched, sample is allowed to relax for 48 hours, at roomtemperature, prior to the determination of elasticity. The length of thedeformation zone in the sample is measured to be d₁. After the 48 hours,it is again deformed at 10 inches per minute for a 200% extension of thedeformation zone of the sample and allowed to relax at the same rate.The sample is removed and after 10 minutes of relaxation the sample ismeasured to have a new length of the deformation zone of d₂. Theelasticity of the sample as a percent is determined as 100*(d₂−d₁)/d₁.

Embodiments of the invention have elasticity, as measured by theprocedure described above, of less than 30%, or less than 20%, or lessthan 10%, or less than 8% or less than 5%.

These values of the elasticity over the range of composition of thecopolymer vary with the tensile strength of the sample as measured bythe 500% tensile modulus. Elasticity of this family of copolymers isthus represented by two criteria: (a) extensibility to 500% elongationwith a measurable modulus (500% tensile modulus) and (b) elasticity froman extension to 200% elongation on a slightly oriented sample asdescribed above. First, the copolymer of embodiments of our inventionshould have a measurable tensile strength at 500% elongation (also knownas 500% tensile modulus), of greater than 0.5 MPa, or greater than 0.75MPa, or greater than 1.0 MPa, or greater than 2.0 MPa; and second, thecopolymer should have the above-described elasticity.

Alternatively, the relationship of elasticity to 500% tensile modulusmay be described. Referring to FIG. 3, elasticity is plotted versus 500%tensile modulus in MPa for copolymers of the invention. The plotted datacorrespond to Samples 5–14 in Table 6 of the Examples herein. A linearregression fit of the data yields a relationship of:Elasticity (%)=0.9348M−1.0625where M is the 500% tensile modulus in MPa. In embodiments of thepresent invention, the elasticity as a function of 500% tensile modulusin MPa is defined by:Elasticity (%)≦0.935M+12; orElasticity (%)≦0.935M+6; orElasticity (%)≦0.935M.Flexural Modulus

Softness of the copolymers of embodiments of the invention may bemeasured by flexural modulus. Flexural modulus is measured in accordancewith ASTM D790, using a Type IV dogbone at crosshead speed of 0.05in/min (1.3 mm/min). The values of the flexural modulus over the rangeof composition of the copolymer vary with the tensile strength of thesample as measured by the 500% tensile modulus. Flexural modulus of thisfamily of copolymers is thus represented by two criteria: (a)extensibility to 500% elongation with a measurable modulus (500% tensilemodulus); and (b) flexural modulus.

Referring to FIG. 2, flexural modulus in MPa is plotted versus 500%tensile modulus in MPa for copolymers of the invention. The plotted datacorrespond to Samples 15–19 in Table 7 of the Examples herein. A singleexponential fit of the data yields a relationship of:Flexural Modulus (MPa)=4.1864e ^(0.269M)where M is the 500% tensile modulus in MPa. In embodiments of thepresent invention, the flexural modulus in MPa as a function of 500%tensile modulus in MPa is defined by:Flexural Modulus≦4.2e ^(0.27M)+50; orFlexural Modulus≦4.2e ^(0.27M)+30; orFlexural Modulus≦4.2e ^(0.27M)+10; orFlexural Modulus≦4.2e ^(0.27M)+2.Ethylene Composition

The composition of ethylene propylene copolymers is measured as ethylenewt. % according to ASTM D3900 as follows. A thin homogeneous film of thecopolymer component, pressed at a temperature of at or greater than 150°C., is mounted on a Perkin Elmer PE 1760 infra red spectrophotometer. Afull spectrum of the sample from 600 cm⁻¹ to 4000 cm⁻¹ is recorded, andthe ethylene weight percent of the copolymer component is calculatedfrom:Ethylene wt. %=82.585−111.987X+30.045X ²where X is the ratio of the peak height at 1155 cm⁻¹ to peak height ateither 722 cm⁻¹ or 732 cm⁻¹, which ever is higher.Molecular Weight and PDI

Techniques for determining the molecular weight (Mn and Mw) andmolecular weight distribution (MWD) are found in U.S. Pat. No.4,540,753, and in Macromolecules, 1988, volume 21, p. 3360 (Verstrate etal).

Melting Point and Heat of Fusion

Melting point and heat of fusion are measured by Differential ScanningCalorimetry (DSC) follows. About 6 to 10 mg of a sheet of the polymerpressed at approximately 200° C. to 230° C. is removed with a punch die.This is annealed at room temperature for 24 hours. At the end of thisperiod, the sample is placed in a Differential Scanning Calorimeter(Perkin Elmer 7 Series Thermal Analysis System) and cooled to about −50°C. to about −70° C. The sample is heated at 20° C./min to attain a finaltemperature of about 200° C. to about 220° C. The thermal output isrecorded as the area under the melting peak of the sample, which istypically peaked at about 30° C. to about 175° C. and occurs between thetemperatures of about 0° C. and about 200° C., and is measured in joulesas a measure of the heat of fusion. The melting point is recorded as thetemperature of the greatest heat absorption within the range of meltingof the sample.

Intermolecular Composition and Tacticity Distribution Determination

Intermolecular composition distribution of the copolymer is measured asdescribed below. Nominally 30 grams of the copolymer is cut into smallcubes with about ⅛″ (3 mm) sides. This is introduced into a thick-walledglass bottle with a screw cap closure, along with 50 mg of Irganox1076,an antioxidant commercially available from Ciba-Geigy Corporation. Then,425 mL of hexane (a principal mixture of normal and iso isomers) isadded to the bottle and the sealed bottle is maintained at 23° C. for 24hours. At the end of this period, the solution is decanted and theresidue is treated with additional hexane for an additional 24 hours. Atthe end of this period, the two hexane solutions are combined andevaporated to yield a residue of the polymer soluble at 23° C. To theresidue is added sufficient hexane to bring the volume to 425 mL and thebottle is maintained at 31° C. for 24 hours in a covered circulatingwater bath. The soluble polymer is decanted and an additional amount ofhexane is added for another 24 hours at 31° C. prior to decanting. Inthis manner, fractions of the copolymers soluble at 40° C., 48° C., 55°C. and 62° C. are obtained at temperature increases of approximately 8°C. between stages. Increases in temperature to 95° C. can beaccommodated if heptane, instead of hexane, is used as the solvent forall temperatures above about 60° C. The soluble polymers are dried,weighed and analyzed for composition, as wt. % ethylene content, by theIR technique described above. Soluble fractions obtained in the adjacenttemperature fractions are the adjacent fractions in the specificationabove.

EXAMPLES Example 1 Ethylene/propylene Copolymerization

Continuous polymerization of the polymer is conducted in a 9 literContinuous Flow Stirred Tank Reactor using hexane as the solvent. Theliquid full reactor has a residence time of 9 minutes and the pressureis maintained at 700 kPa. A mixed feed of hexane, ethylene and propyleneis pre-chilled to approximately −30° C. to remove the heat ofpolymerization, before entering the reactor. Solutions ofcatalyst/activator in toluene and the scavenger in hexane are separatelyand continuously admitted into the reactor to initiate thepolymerization. The reactor temperature is maintained between 35 and 50°C., depending on the target molecular weight. The feed temperature isvaried, depending on the polymerization rate to maintain a constantreactor temperature. The polymerization rate is varied from about 0.5kg/hr to about 4 kg/hr. Hexane at 30 kg/hr is mixed with ethylene at 717g/hr and propylene at 5.14 kg/hr and fed to the reactor. Thepolymerization catalyst, dimethylsilyl bridged bis-indenyl hafniumdimethyl activated 1.1 molar ratio with N′,N′-dimethylanilinium-tetrakis (pentafluorophenyl)borate is introduced at the rateof at 0.0135 g/hr. A dilute solution of triisobutyl aluminum isintroduced into the reactor as a scavenger of catalyst terminators; arate of approximately 111 mol of scavenger per mole of catalyst isadequate for this polymerization After the polymerization reaches steadystate, a representative sample of the polymer produced in thispolymerization is collected, and then steam-distilled to isolate thepolymer. The polymerization rate is measured as 3.7 kg/hr. The polymerproduced in this polymerization has an ethylene content of 14%, ML (1+4)125° C. (Mooney Viscosity) of 13.1 and has isotactic propylenesequences.

Variations in the composition of the polymer are obtained principally bychanging the ratio of ethylene to propylene. Molecular weight of thepolymer is varied by either changing the reactor temperature or bychanging the ratio of total monomer feed rate to the polymerizationrate.

In the manner described in Example 1 above, polymers of the abovespecification are synthesized. These are described in the tables below.Table 2 describes the results of the GPC, composition, and DSC analysisfor the polymers.

TABLE 2 Analysis of the polymers ¹³C NMR RESULTS DSC Results Sam- 2,11,3 Heat of Melting ple Ethylene Triad insertion insertion fusion Point# (wt %) (mm) (%) (%) m/r (J/g) (° C.) #1 11.0 90.1 0.63 0.098 7.1 19 49#2 18.5 91.3 0.84 0.12 6.2 1.8 50 #3 9.4 91.8 0.80 0.086 6.9 27 69 #414.1 90.6 0.74 0.13 7.7 8.0 51

TABLE 3 Fractional solubility of copolymer (hexane) Wt % soluble at TSample # 23° C. 31° C. 40° C. 1 39.2 60.0 0.5 2 97.6 2.1 3 0.7 52.3 48.14 99.3 0.7

Table 4 describes the composition of the fractions of the copolymerobtained in Table 3. Only fractions which have more than 4% of the totalmass of the polymer have been analyzed for composition.

TABLE 4 Composition of fractions of the copolymer component obtained inTable 3 Composition (wt % C2) for fraction soluble at T Sample # 23° C.31° C. 40° C. 1 10.8 11.3 — 2 17.9 — 3 —  9.9 10.2 4 14.5 —

The experimental inaccuracy in the determination of the ethylene contentis believed to be approximately 0.4 wt % absolute.

TABLE 5 Mechanical properties of the polymers Mechanical PropertiesTensile Strength 500% Tensile Modulus Sample # (psi, MPa) (psi, MPa)Elasticity (%) 1 3226.5, 22.25 1412, 9.74 17 2  334.0, 2.30  129, 0.889 1.5 3 5041.3, 34.76 2300, 15.86 24 4 1277.7, 8.810  387, 2.67  0

TABLE 6 Mechanical properties of the polymers Composition MechanicalProperties Ethylene Content 500% Tensile Elasticity Sample # (wt %)Modulus (MPa) (%) 5 12.4 6.8 3.1 6 12.0 7.9 1.6 7 17.0 0.9 1.6 8 11.19.9 18.8 9 10.8 8.9 6.4 10 12.1 6.9 3.1 11 13.4 6.4 1.6 12 14.8 2.7 0 1316.4 0.6 3.1 14 13.4 7.1 4.7

TABLE 7 Mechanical properties of the polymers Composition MechanicalProperties Ethylene Content 500% Tensile Flexural Sample # (wt %)Modulus (MPa) Modulus (MPa) 15 12.0 7.9 26.8 16 14.8 2.7 9.2 17 17.0 0.95.6 18 10.8 8.9 40.1 19 10.0 10.3 93.0

Example 2 Ethylene/propylene Copolymerization

Continuous Polymerization of the polymer was conducted in a 1 literinternal volume Continuous Flow Stirred Tank Reactor using hexane as thesolvent. The liquid full reactor had a variable residence time ofapproximately 9 to 15 minutes (as described in the table below) and thepressure was maintained at 700 kpa. A mixed feed of Hexane, ethylene andpropylene was pre-chilled to approximately −30° C. to remove the heat ofpolymerization, before entering the reactor. The pre-chillingtemperature was adjusted to maintain indicated solution polymerizationtemperature. The solution of catalyst/activator in Toluene and thescavenger in hexane were separately and continuously admitted into thereactor to initiate the polymerization. The reactor temperature wasmaintained between 50 and 95° C. and the polymerization rate could bevaried from 0.1 kg/hr to 0.5 kg/hr as shown in Tables 8 through 13,below.

Hexane, ethylene, and propylene were fed to the reactor at the ratesshown in Tables 8 through 12. The polymerization catalyst, dimethylsilyl bridged bis-indenyl Hafnium dimethyl was activated in vitro with1:1 molar ratio with NCA indicated below in the tables and introducedinto the polymerization reactor at the rate of 0.0135 g/hr. Two NCA'swere used: N′,N′-Dimethyl anilinium-tetrakis (pentafluorophenyl)borate(A1) and N,N′-Dimethyl anilinium-tetrakis (heptafluoro-1-napthyl)borate(A2). A dilute solution of triisobutyl aluminum was introduced into thereactor as a scavenger of catalyst terminators. A rate of approximately1.11 mole of scavenger per mole of catalyst was adequate for thispolymerization. After five residence times of steady polymerization, arepresentative sample of the polymer produced in this polymerization wascollected. The solution of the polymer was withdrawn from the top, andthen steam distilled to isolate the polymer. The polymerization rate wasmeasured as shown in the tables below. The polymer produced in thispolymerization was. analyzed for ethylene content by FT-IR, molecularweight averages by GPC. Crystallinity was measured by DSC and the amountof mm triads of propylene residues in the polymer chain was determinedby ¹³C NMR. As we have mentioned above the crystallinity and mm triadsdetermination are redundant determinations since the crystallinity ofthe polymers are dependent only on the isotactic propylene residues.

The data in the tables below shows the effect of the changes in thepolymerization conditions (temperature, NCA and residual monomerconcentration) on propylene/ethylene copolymers made at two distinctcompositions. The first composition contains approximately 7 wt %ethylene and the second contains approximately 14 wt % ethylene. Thedata will show that the benefits of the invention are available acrossthe composition range for these propylene-ethylene polymers.

This example illustrates the difference in the polymerization of A1 andA2 with the polymerization being conducted at a range of increasingtemperatures between 50° C. and 95° C. For each polymerization conditiontemperature the same polymerization monomer, solvent and catalyst feedare used to make polymers of essentially identical composition. For anyactivator the rise in the polymerization temperature lowers thecrystallinity and molecular weight of the polymer, however thereplacement of A1 by A2 raises both the crystallinity as well as themolecular-weight.

TABLE 8 Polymerization Conditions and Polymer Products PolymerizationReactor Steady Polymer State mm Hexane Polymer C₃ ⁼ C₂ ⁼ % Sample TempSolvent Ethylene Propylene Product (moles/ wt ¹³C Mw Tm # NCA (° C.)(kg/hr) (g/hr) (g/hr) (kg/hr) l) %* NMR (×1000) (° C.) 20-C A1 50 3.5624 438 0.30 0.58 6.5 92 148 91 21-C A1 65 3.56 24 438 0.29 0.62 6.8 8567 85 22-C A1 80 3.56 24 438 0.29 0.63 7.1 83 44 71 23-C A1 95 3.56 24438 0.28 0.69 8.4 77 22 62 24 A2 50 3.56 24 438 0.30 0.59 7.2 93 290 11025 A2 65 3.56 24 438 0.29 0.65 7.5 91 215 101 26 A2 80 3.56 24 438 0.280.69 7.7 90 150 96 27 A2 95 3.56 24 438 0.28 0.68 8.5 89 80 83*Understood to mean units derived from ethyleneSamples 20-C through 23-C (Comparative) and 24 through 27:

This example illustrates the difference in the polymerization of A1 andA2 with the polymerization being conducted at a temperature of 95° C.During each series of polymerization the composition of the polymer isheld essentially constant but the residual level of monomer isprogressively raised. For both A1 and A2 activated polymerization therise in the residual monomer concentration raises the crystallinity ofthe propylene residues in the polymer.

TABLE 9 Polymerization Conditions and Polymer Products PolymerizationReactor Hexane Polymer Steady Polymer Sample Temp Solvent EthylenePropylene Product State C₃ C₂ ⁼ mm % Mw Tm # NCA (° C.) (kg/hr) (g/hr)(g/hr) (kg/hr) (mole/l) wt % ¹³C NMR (×1000) (° C.) 28C A1 95 3.56 24438 0.28 0.69 8.4 77 22 62 29C A1 95 3.17 24 438 0.27 0.81 8.7 79 25 6430C A1 95 3.17 27.6 504 0.32 0.83 6.9 81 26 66 31C A1 95 3.17 31.7 5790.40 0.84 7.4 81 28 67 32 A2 95 3.56 24 438 0.29 0.65 7.8 89 87 64 33 A295 3.56 27 504 0.36 0.63 7.8 91 88 72 34 A2 95 3.17 27 504 0.35 0.73 7.891 101 87 35 A2 95 3.17 31.2 582 0.40 0.84 7.8 94 102 95 36 A2 95 2.7731.2 582 0.42 0.85 7.8 95 120 102Samples 28-C through 31-C (Comparative) and 32 through 36:

This example illustrates the difference in the polymerization of A1 andA2 with the polymerization being conducted at a temperature of 95° C.During each series of polymerization the composition of the polymer isheld essentially constant but the residual level of monomer isprogressively raised. For both A1 and A2 activated polymerization therise in the residual monomer concentration raises the crystallinity ofthe propylene residues in the polymer. The examples differ from the datain examples immediately earlier in that a propylene-ethylene copolymerhaving a higher ethylene content was made. These data in conjunctionindicate that the effect of the replacement of A1 by A2 is not limitedby the ethylene content of the polymer.

TABLE 10 Polymerization Conditions and Polymer Products Polymerizationreactor Hexane Polymer Steady Polymer Sample Temp Solvent EthylenePropylene Product State C₃ ⁼ C₂ ⁼ Mw Tm # NCA (° C.) (kg/hr) (g/hr)(g/hr) (kg/hr) (mole/l) wt % (×1000) (° C.) H_(f)(j/g) 37C A1 95 3.56 45438 0.36 0.52 16.9 28 no na 38C A1 95 3.56 52.2 504 0.37 0.70 14.8 34 nona 39C A1 95 3.17 52.2 504 0.37 0.79 17.8 34 no na 40C A1 95 3.17 60 5820.35 1.13 16.9 45 47 0.14 41C A1 95 2.77 60 582 0.41 1.01 15.3 47 480.78 42 A2 95 3.56 45 438 0.36 0.52 17.2 108 45 0.22 43 A2 95 3.56 52.2504 0.37 0.70 14.9 107 46 6.4 44 A2 95 3.17 52.2 504 0.37 0.75 15.1 11045 6.8 45 A2 95 3.17 60 582 0.35 1.14 17.6 113 47 5.7 46 A2 95 2.77 60582 0.41 1.04 17.0 123 48 6.8Samples 37-C through 41-C (Comparative) and 42 through 46:

This example illustrates the difference in the polymerization of A1 andA2 with the polymerization being conducted at a range of increasingtemperatures between 50° C. and 95° C. For each polymerization conditiontemperature the same polymerization monomer, solvent and catalyst feedare used to make polymers of essentially identical composition. For anyactivator the rise in the polymerization temperature lowers thecrystallinity and molecular weight of the polymer, however thereplacement of A1 by A2 raises both the crystallinity as well as themolecular weight. The examples differ from the data in examples 1–8earlier in that a propylene-ethylene copolymer having a higher ethylenecontent was made. These data in conjunction indicate that the effect ofthe replacement of A1 by A2 is not limited by the ethylene content ofthe polymer.

TABLE 11 Polymerization Conditions and Polymer Products PolymerizationReactor Hexane Polymer Steady Polymer Sample Temp Solvent EthylenePropylene Product State C₃ ⁼ C₂ ⁼ Mw Tm # NCA (° C.) (kg/hr) (g/hr)(g/hr) (kg/hr) (mole/l) wt % (×1000) (° C.) H_(f)(J/g) 47C A1 50 3.56 45438 0.31 0.66 14.9 113 43 6.3 48C A1 65 3.56 45 438 0.30 0.68 15.2 86 440.7 49C A1 80 3.56 45 438 0.29 0.70 15.0 67 no na 50C A1 95 3.56 45 4380.30 0.69 15.3 33 no na 51 A2 50 3.56 45 438 0.31 0.65 14.0 245 43 17 52A2 65 3.56 45 438 0.30 0.68 15.0 208 44 13 53 A2 80 3.56 45 438 0.290.71 15.5 142 46 9.1 54 A2 95 3.56 45 438 0.30 0.69 15.3 91 47 2.8Samples 47-C Through 50-C (Comparative) and 51 Through 54:

In these examples similar data is shown for propylene ethylene polymerscontaining isotactic propylene crystallinity which have thepolymerization conducted at a higher steady state propyleneconcentration than those reported previously above. Comparative examples69-C to 76-C have data for polymers of the similar composition made withA1.

Samples 55 Through 68 and 69-C Through 76-C (Comparative):

The heat of fusion data for the polymers of examples 55 through 68 andthe data for the comparative examples 69-C to 76-C is plotted in FIG. 5which shows that the activators of the invention have an ability to makea polymer of a higher crystallinity than the comparative examples.

Samples 77-C through 80-C (Comparative):

Comparative examples 77-C to 80-C show the comparison of the Mooneyviscosity (Mooney viscosity measured as ML (1+4) at 127° C. in Mooneyunits according to ASTM D-1646) of the polymer made with A1 forcomparison to the data in examples 55 through 68. Since the Mooneyviscosity of the copolymers is strongly dependent on the steady satemonomer concentrations the data is plotted as a function of the monomerconcentration and the polymerization temperature. The data demonstratesthat the copolymers made with A1 have a lower Mooney viscosity thanthose made with A2 at similar or higher polymerization temperature. Thisis shown in FIG. 6.

TABLE 12 Polymerization Conditions and Polymer Products PolymerizationReactor Hexane Polymer Steady State Polymer Sample Temp Solvent EthylenePropylene Product C₃ ⁼ wt % in C₂ ⁼ ML@12 Tm H_(f) # NCA (° C.) (kg/hr)(g/hr) (g/hr) (kg/hr) Hexane wt % 7° C. (° C.) (J/g) 19 A2 60 3.56 75812 0.49 10.8 13.70 15.3 45 19.3 20 A2 60 3.56 75 812 0.44 12.3 14.7016.1 46 11.14 21 A2 60 3.56 75 812 0.41 13.2 17.92 20.6 46 10.6 22 A2 703.56 75 812 0.43 12.7 16.10 11.6 47 8.6 23 A2 70 3.56 65 812 0.35 14.514.70 16.6 46 13.5 24 A2 70 3.56 60 812 0.36 14.1 13.57 16.9 46 15.8 24A2 70 3.56 58 812 0.26 16.4 14.76 19.9 46 13.4 26 A2 80 3.56 75 812 0.5011.1 16.20 6.7 45 16.5 27 A2 80 3.56 70 812 0.45 12.2 15.97 7.9 45 15.528 A2 80 3.56 70 812 0.40 13.3 15.41 11 46 12 29 A2 90 3.56 75 812 0.4911.1 14.32 4.1 46 15 30 A2 90 3.56 75 812 0.41 13.2 16.15 4.8 49 7.3 31A2 90 3.56 67 812 0.36 14.2 14.94 5.2 46 13.2 32 A2 90 3.56 60 812 0.2816.0 15.26 6.6 46 9.8

TABLE 13 Polymer Products Polymer Sample # NCA C₂ = wt % Tm (° C.) H_(f)(J/g) 69-C A1 11 45 19 70-C A1 11.9 46 19 71-C A1 12.4 46 17 72-C A1 1347 16 73-C A1 14.1 46 8 74-C A1 14.2 46 8 75-C A1 16.3 46 3.5 76-C A118.5 45 1.8

TABLE 14 Polymerization Conditions and Polymer Products PolymerizationReactor Polymer Hexane Polymer Steady Sample Temp Solvent EthylenePropylene Product State C₃ ⁼ # NCA (° C.) (kg/hr) (g/hr) (g/hr) (kg/hr)wt % in C6 C₂ wt % ML@127° C. 77-C A1 60 3.56 75 812 0.49 10.8 12.83 2.878-C A1 60 3.56 75 812 0.44 12.3 11.54 3.3 79-C A1 60 3.56 75 812 0.4113.2 12.31 5.4 80-C A1 60 3.56 75 812 0.43 12.7 14.63 9.8

Although the present invention has been described in considerable detailwith reference to certain aspects and embodiments thereof, other aspectsand embodiments are possible. For example, while ethylene propylenecopolymers have been exemplified, other copolymers are alsocontemplated. Therefore, the spirit and scope of the appended claimsshould not be limited to the description of the versions containedherein.

Certain features of the present invention are described in terms of aset of numerical upper limits and a set of numerical lower limits. Itshould be appreciated that ranges from any lower limit to any upperlimit are within the scope of the invention unless otherwise indicated.

All patents, test procedures, and other documents cited in thisapplication are fully incorporated by reference to the extent suchdisclosure is not inconsistent with this application and for alljurisdictions in which such incorporation is permitted.

1. A process comprising: a) polymerizing propylene and ethylenecomonomers in a solution process at a reaction temperature at or above60° C., with a polymerization catalyst complex comprising: i) anorganometallic Group 4 transition metal compound; and ii) an activatingcocatalyst, wherein said catalyst complex produces stereospecificpolypropylene, and b) recovering a propylene copolymer containing unitsderived from propylene in an amount greater than or equal to 75 weightpercent, and units derived from ethylene in an amount of from 5 to 25weight percent, wherein the copolymer has a melting point of fromgreater than 35° C. to less than 110° C., and a weight average molecularweight of:Mw>6.10*P*e ^((3370/T)) wherein: Mw=the weight average molecular weightT=the polymerization reaction temperature in degrees Kelvin P=the steadystate propylene concentration in the polymerization reaction zone inmoles per liter, wherein said process occurs under homogeneouspolymerization conditions that are adiabatically conducted in acontinuous polymerization process.
 2. The process of claim 1 whereinsaid polymerization conditions are conducted in a continuous process ata pressure of at least 500 bar.
 3. The process of claim 1 wherein saidGroup 4 metal is hafnium.
 4. A process comprising: a) polymerizingpropylene and ethylene comonomers in a solution process at a reactiontemperature at or above 60° C., with a polymerization catalyst complexcomprising: i) on organometallic Group 4 transition metal compound; andii) an activating cocatalyst, wherein said catalyst complex producesstereospecific polypropylene; and b) recovering a propylene copolymercontaining units derived from propylene in an amount greater than orequal to 75 weight percent, and units derived from ethylene in an amountof from 5 to 25 weight percent, wherein the copolymer has a meltingpoint of from greater than 35° C. to less than 110° C., and a triadtacticity of greater than 85%, wherein said process occurs underhomogeneous polymerization conditions that are adiabatically conductedin a continuous polymerization process.
 5. The process of claim 4wherein said polymerization conditions are conducted in a continuousprocess at a pressure of at least 500 bar.
 6. The process of claim 4wherein said Group 4 metal is hafnium.
 7. A process comprising: a)polymerizing propylene and ethylene comonomers in a solution process ata reaction temperature at or above 60° C., with a polymerizationcatalyst complex comprising: i) an organometallic Group 4 transitionmetal compound; and ii) an activating cocatalyst, precursor ioniccompound comprising a halogenated tetra-aryl-substituted Group 13 anionwherein each aryl substituent contains at least two cyclic aromaticrings. wherein said catalyst complex produces stereospecificpolypropylene; and b) recovering a propylene copolymer containing unitsderived from propylene in an amount greater than or equal to 75 weightpercent, and units derived from ethylene in an amount of from 5 to 25weight percent, wherein the copolymer has a melting point of fromgreater than 35° C. to less than 110° C., and a weight average molecularweight of:MW>6.10*P*e ^((3370/T)) wherein: Mw=the weight average molecular weightT=the polymerization reaction temperature in degrees Kelvin P=the steadystate propylene concentration in the polymerization reaction zone inmoles per liter, wherein said process occurs under homogeneouspolymerization conditions that are adiabatically conducted in acontinuous polymerization process.
 8. The process of claim 7 whereinsaid polymerization conditions are conducted in a continuous process ata pressure of at least 500 bar.
 9. A process comprising: a) polymerizingpropylene and ethylene comonomers in a solution process at a reactiontemperature at or above 60° C., with a polymerization catalyst complexcomprising: i) an organometallic Group 4 transition metal compound; andii) an activating cocatalyst, precursor ionic compound comprising ahalogenated tetra-aryl-substituted Group 13 anion wherein each arylsubstituent contains at least two cyclic aromatic rings, wherein saidcatalyst complex produces stereospecific polypropylene; and b)recovering a propylene copolymer containing units derived from propylenein an amount greater than or equal to 75 weight percent, and unitsderived from ethylene in an amount of from 5 to 25 weight percent,wherein the copolymer has a melting point of from greater than 35° C. toless than 110° C., and a triad tacticity of greater than 85%, whereinsaid process occurs under homogeneous polymerization conditions that areadiabatically conducted in a continuous polymerization process.
 10. Theprocess of claim 9 wherein said polymerization conditions are conductedin a continuous process at a pressure of at least 500 bar.
 11. A processcomprising: a) polymerizing propylene and ethylene comonomers in asolution process at a reaction temperature at or above 60° C., with apolymerization catalyst complex comprising: i) an organometallic Group 4transition metal compound; and ii) an activating cocatalyst comprisingN,N-dimethylanilinium tetrakis(perfluoronapthyl)boron; wherein saidcatalyst complex produces stereospecific polypropylene; and b)recovering a propylene copolymer containing units derived from propylenein an amount greater than or equal to 75 weight percent, and unitsderived from ethylene in an amount of from 5 to 25 weight percentwherein the copolymer has a melting point of from greater than 35° C. toless than 110° C. and a triad tacticity of greater than 85%, whereinsaid process occurs under homogeneous polymerization conditions that areadiabatically conducted in a continuous polymerization process.
 12. Theprocess of claim 11 wherein said homogeneous polymerization conditionsare conducted in a continuous process at a pressure of at least 500 bar.13. A polymeric product prepared by olefin polymerization said productcomprising a copolymer comprising 5 to 25% by weight of ethylene-derivedunits and 95 to 75% by weight of propylene-derived units, the copolymerhaving; (i) a melting point of less than 90° C.; (ii) a relationship ofelasticity to 500% tensile modulus such that Elasticity ≦0.935M+12,where elasticity is in percent and M is the 500% tensile modulus in MPa;and (iii) a relationship of flexural modulus to 500% tensile modulussuch that Flexural Modulus ≦4.2e^(0.27M)+50, where flexural modulus isin MPa and M is the 500% tensile modulus in MPa; and wherein saidpolymeric product is prepared using a catalyst system comprising acatalyst and an activator, the activator comprising anions containing asingle coordination complex of a charge-bearing boron or aluminum corewherein said core is tetra-aryl-substituted and each aryl substituentcontains at least two cyclic aromatic rings.
 14. A polymeric productprepared by olefin polymerization said product comprising a copolymercomprising 5 to 25 % by weight of ethylene-derived units and 95 to 75%by weight of propylene-derived units, the copolymer having: (i) amelting point of less than 90° C.; (ii) a relationship of elasticity to500% tensile modulus such thatElasticity≦0.935M+12, where elasticity is in percent and M is the 500%tensile modulus in MPa; and (iii) a relationship of flexural modulus to500% tensile modulus such thatFlexural Modulus≦4.2e ^(0.27M)+50, where flexural modulus is in MPa andM is the 500% tensile modulus in MPa; and wherein said polymeric productis prepared using a catalyst system comprising a catalyst and anactivator, the activator comprising anions containing a singlecoordination complex of a charge-bearing boron or aluminum core whereinsaid core has three halogenated aryl-ligands, wherein each arylsubstituent contains at least two cyclic aromatic rings, and oneacetyl-aryl moiety ligand.